TOOLS · TROUBLESHOOTING
Conveyor Troubleshooting by Symptom
Find the fault by symptom: what it looks like, where to look first, why it happens and the field-proven fix — each linked to the HBXM part that solves it.
Quick triage — symptom to area
Scan this before you climb the structure. It maps the fault to the area most often responsible and the first thing to check.
| Symptom | Likely area | Severity | First check |
|---|---|---|---|
| Belt mistracking (running off) | Conveyor Belt | High | Align the frames, replace seized idlers, fit training idlers, centre the chute |
| Splice failure (joint opening) | Conveyor Belt | High | Use a vulcanized splice for demanding duty and inspect on schedule |
| Belt cut by tramp metal | Conveyor Belt | High | Fit a metal detector and tear detection, and add buffer beds at the load point |
| Abnormal top-cover wear | Conveyor Belt | Medium | Lower the speed if possible, add impact beds, correct alignment |
| Belt edge damage or curling | Conveyor Belt | Medium | Re-align the guides, clear spillage, and fix tracking and pulley crowning |
| Belt elongation / excess stretch | Conveyor Belt | Medium | Check the belt rating, extend the take-up travel, verify the carcass class |
| Belt stiff or cracked in cold | Conveyor Belt | Medium | Specify a cold-resistant cover grade and warm up the belt gently before full load |
| Motor overload or repeated trip | Drive System | High | Check resistances and belt condition, verify motor sizing, use a soft start |
| Gearbox oil leak or overheating | Drive System | High | Use the specified oil, check the level, verify the duty, clean the breather |
| Backstop not holding | Drive System | High | Inspect and replace the backstop and verify the rotation direction |
| Drive vibration or noise | Drive System | Medium | Re-align the coupling, balance the pulley, anchor the base |
| Idler bracket or frame breakage | Idlers & Rollers | High | Inspect the loading zone, uprate frames to the correct CEMA class, add impact support |
| Bearing overheating | Idlers & Rollers | High | Use the specified grease and sealed housings |
| Idler noise or seizure | Idlers & Rollers | Medium | Fit sealed lubricated-for-life idlers and replace at the first abnormal sound |
| Excessive belt sag between idlers | Idlers & Rollers | Medium | Reduce carrying idler spacing and raise take-up tension |
| Idler shell wear or grooving | Idlers & Rollers | Low | Use thicker-wall or ceramic-shell idlers for abrasive duty and rotate stock |
| Pulley lagging detaching | Pulleys | High | Re-lag with a hot-vulcanized cover and keep the pulley dry |
| Belt slipping at the drive pulley | Pulleys | High | Increase take-up tension, re-lag with grooved or ceramic rubber, use a soft start |
| Material build-up on pulleys | Pulleys | Medium | Fit primary and secondary cleaners and add a tail scraper |
| Pulley shell or shaft wear | Pulleys | Medium | Protect with lagging, correct any slip, and inspect the shaft |
| Take-up carriage stuck | Structure & Take-up | High | Free the rails, service the screw, clear the counterweight travel |
| Conveyor stalls on start-up | Structure & Take-up | High | Pre-tension correctly, use a soft start, and start with the belt empty |
| Chute blockage | Transfer & Cleaning | High | Adjust the chute angle, fit wear liners, and control the feed size |
| Material spillage along the belt | Transfer & Cleaning | Medium | Fit buffer beds and skirt seals at the transfer and size for rated capacity |
| Dust emission at transfer | Transfer & Cleaning | Medium | Enclose the transfer, seal the skirts, and add spray or dry-fog suppression |
| Carry-back build-up on return run | Transfer & Cleaning | Medium | Fit primary and secondary cleaners and add a plough cleaner |
| Skirt rubber worn or leaking | Transfer & Cleaning | Low | Replace the skirt rubber, set the correct gap, use a wear-resistant grade |
Faults by area
Filter by area
Severity
Search
01 Idlers & Rollers 5 faults
Bearing overheating
HighWrong grease, contamination, over-tight fit or misalignment.
Field fixUse the specified grease and sealed housings; correct the fit and alignment.
See the HBXM part →Idler bracket or frame breakage
HighOverload, fatigue, impact at the loading zone, poor welds.
Field fixInspect the loading zone, uprate frames to the correct CEMA class, add impact support.
See the HBXM part →Excessive belt sag between idlers
MediumIdler spacing too wide, tension too low, heavy load.
Field fixReduce carrying idler spacing and raise take-up tension; check against CEMA/DIN sag limit.
See the HBXM part →Idler noise or seizure
MediumContaminated or water-ingressed bearing, over-greasing, worn seal.
Field fixFit sealed lubricated-for-life idlers and replace at the first abnormal sound.
See the HBXM part →Idler shell wear or grooving
LowAbrasive material, long service life, off-centre loading.
Field fixUse thicker-wall or ceramic-shell idlers for abrasive duty and rotate stock.
See the HBXM part →02 Pulleys 4 faults
Belt slipping at the drive pulley
HighLow tension, worn or wet lagging, overloaded start.
Field fixIncrease take-up tension, re-lag with grooved or ceramic rubber, use a soft start.
See the HBXM part →Pulley lagging detaching
HighPoor bond, water or oil ingress, overload.
Field fixRe-lag with a hot-vulcanized cover and keep the pulley dry.
See the HBXM part →Material build-up on pulleys
MediumWet or sticky material, missing or worn cleaner.
Field fixFit primary and secondary cleaners and add a tail scraper.
See the HBXM part →Pulley shell or shaft wear
MediumAbrasive carry-back, belt slip, fatigue at the hub.
Field fixProtect with lagging, correct any slip, and inspect the shaft.
See the HBXM part →03 Conveyor Belt 7 faults
Belt cut by tramp metal
HighUndetected metal in the feed, no metal detector, no impact cushioning.
Field fixFit a metal detector and tear detection, and add buffer beds at the load point.
See the HBXM part →Belt mistracking (running off)
HighMisaligned frame, seized idler, uneven tension, off-centre load.
Field fixAlign the frames, replace seized idlers, fit training idlers, centre the chute.
See the HBXM part →Splice failure (joint opening)
HighWrong splice type, under-cure, overload, impact at the joint.
Field fixUse a vulcanized splice for demanding duty and inspect on schedule.
See the HBXM part →Abnormal top-cover wear
MediumHigh speed, sharp material impact, misaligned idlers.
Field fixLower the speed if possible, add impact beds, correct alignment.
See the HBXM part →Belt edge damage or curling
MediumSide guide misaligned, spillage rubbing the edge, wrong pulley crown.
Field fixRe-align the guides, clear spillage, and fix tracking and pulley crowning.
See the HBXM part →Belt elongation / excess stretch
MediumLoad beyond belt rating, take-up travel too short, wrong carcass.
Field fixCheck the belt rating, extend the take-up travel, verify the carcass class.
See the HBXM part →Belt stiff or cracked in cold
MediumWrong low-temperature rubber grade, long shutdown in freezing conditions.
Field fixSpecify a cold-resistant cover grade and warm up the belt gently before full load.
04 Transfer & Cleaning 5 faults
Chute blockage
HighSticky material, wrong slope, oversize lumps.
Field fixAdjust the chute angle, fit wear liners, and control the feed size.
See the HBXM part →Carry-back build-up on return run
MediumNo or worn cleaner, sticky material, no plough.
Field fixFit primary and secondary cleaners and add a plough cleaner.
See the HBXM part →Dust emission at transfer
MediumOpen transfer, dry material, no suppression.
Field fixEnclose the transfer, seal the skirts, and add spray or dry-fog suppression.
See the HBXM part →Material spillage along the belt
MediumPoor skirting, worn seal, overloaded belt, mistracking.
Field fixFit buffer beds and skirt seals at the transfer and size for rated capacity.
See the HBXM part →Skirt rubber worn or leaking
LowAbrasion, wrong gap, hardened rubber.
Field fixReplace the skirt rubber, set the correct gap, use a wear-resistant grade.
See the HBXM part →05 Drive System 4 faults
Backstop not holding
HighWorn sprags, wrong rotation sense, low oil.
Field fixInspect and replace the backstop and verify the rotation direction.
See the HBXM part →Gearbox oil leak or overheating
HighWrong oil grade, low oil level, overload, blocked breather.
Field fixUse the specified oil, check the level, verify the duty, clean the breather.
See the HBXM part →Motor overload or repeated trip
HighOverload, excessive resistances, cold stiff belt, wrong motor sizing.
Field fixCheck resistances and belt condition, verify motor sizing, use a soft start.
See the HBXM part →Drive vibration or noise
MediumMisaligned coupling, unbalanced pulley, loose base.
Field fixRe-align the coupling, balance the pulley, anchor the base.
See the HBXM part →06 Structure & Take-up 2 faults
Conveyor stalls on start-up
HighLow pre-tension, high static friction, cold stiff belt, under-powered start.
Field fixPre-tension correctly, use a soft start, and start with the belt empty.
See the HBXM part →Take-up carriage stuck
HighSeized screw, jammed rail, blocked counterweight travel.
Field fixFree the rails, service the screw, clear the counterweight travel.
See the HBXM part →Still stuck on a fault?
Send us photos and the belt specs — our engineers will diagnose the cause and quote the right component. Or use the configurator to specify a replacement.
Ask our engineers →